Installation and maintenance manual Manuel d’installation et de maintenance Installations- und Wartungshandbuch Manuale di installazione e di manutenzione Manual de instalación y de mantenimiento SysFreeCool English 100 550 kW Français Deutsch Italiano Español Free-cooling module Module Free-cooling Módulo Free-cooling Modulo Free-Cooling Free-cooling modul Part number / Code / Code / Codice / Código: 366240/E Supersedes / Annule et remplace / Annulliert und ersetzt / Annulla e sostituisce / Anula
1 - FOREWORD 7 - PRODUCT DESCRIPTION 1.1 Introduction...........................................................................2 7.1 General Information.............................................................23 1.2 Warranty...............................................................................2 7.2 Body and Frame..................................................................23 1.3 Emergency stop/Normal stop................................................2 7.3 Heat recovery coils.....
11--Introdução Foreword 1.1 Introduction 1.3 Emergency stop / Normal stop Units, manufactured to state-of-the-art design and implementation standards, ensure top performance, reliability and fitness to any type of air-conditioning systems. The emergency stop of the unit can be enabled using the master switch on the control panel (move down the lever). For a normal stop, press the relevant push-buttons.
English 2 - Safety 2.1 Foreword These units must be installed in conformity with the provisions of Machinery Directive 2006/42/EC, Pressure Equipment Directive 2014/68/EU, Electromagnetic Compability Directive 2014/30/EU, as well as with other regulations applicable in the country of installation. If these provisions are not complied with, the unit must not be operated.
2 - Safety (continued) 2.2 Definitions n OWNER: means the legal representative of the company, body or individual who owns the plant where unit has been installed; he/she has the responsibility of making sure that all the safety regulations specified in this manual are complied with, along with the national laws in force.
n check the proper grounding of the unit before start-up The following precautions must be always adopted: n check all the electrical connections, the connecting cables, and in particular the insulation; replace worn or damaged cables n never scatter the fluids of the hydraulic circuit in the surrounding environment n periodically check the board’s internal wiring n n do not use cables having an inadequate section or flying connections, even for limited periods of time or in an emergency when re
2 - Safety (continued) 2.7 Safety labels Identification of the unit Outside, on the right-hand front column Sequence phase control on the electrical board CODICE PRODOTTO NEUTRO PRODUCT CODE 75 MODELLO MODEL 0425 MO.NO MATRICOLA SERIAL NO. ANNO DI COSTRUZIONE Manuf. Year REFR. CIRCUIT GWP 1 2 3 4 CHARGE (Kg) (tCO₂eq) PS (LATO ALTA / LATO BASSA) bar PS (HIGH / LOW SIDE) TS (ALTA / BASSA) °C TS (HIGH / LOW) ALIM.
Electrical warning Adjacent to the master switch English 2 - Safety (continued) Grounding connection on the electrical board, adjacent to the connection ATTENZIONE ! ATTENTION ! Prima di Enlever aprire togliere l’alimentation tensione electrique avant d’ouvrir CAUTION ! ATENCION ! ACHTUNG ! Vor offnen des Disconnect Cortar la corrente antes gehauses electrical de abrir hauptschalter supply before el aparato ausschalten opening Final Test Certificate - Inside the external door Read the instruction on
3 - Transport, Lifting and Positioning Units are supplied assembled (apart from standard antivibrating rubber supports, that will be installed on site). It is recommended to use a spacer to prevent cables from damaging the unit (see the figure). 3.1 Inspection When the unit is delivered, it is recommended to check it carefully and to identify any damage occurred during transportation. The goods are shipped ex-factory, at the buyer’s risk.
The eyebolts must be mounted on the unit whenever it shall be displaced and then lifted again. During the lifting and handling of the unit, be careful not to damage the finned pack of the coils positioned on the sides of the unit. WARNING WARNING WARNING 3.3 Anchoring The sides of the unit must be protected by cardboard or plywood sheets.
4 - Installation 4.1 Positioning of the unit DANGER 4.2 Spring Isolator Installation Before installing the unit, make sure that the structure of the building and/or the supporting surface can withstand the weight of the appliance. The weights of the units are listed in Chapter 8 of this manual. n Prepare the base, that must be flat and plane. n Lift the appliance and insert shock absorbers as follows: These units have been designed for outdoor installation on a solid surface.
4.3 External Water Circuit The expansion tank shall be dimensioned in such a way that it can absorb a 2% expansion of the total volume of the water in the plant (exchanger, pipelines, uses and storage tank, if available). The flow switch and the filter water, although not included in the supply, must always be fitted such as plant components. Their installation is mandatory for warranty.
4 - Installation (continued) Hydraulic Diagram - Stand Alone D E 14 3 12 11 I L Y 11 H 8 5 12 G 10 INLET 8 9 OUTLET 8 12 COMPONENTS 1 Plate heat exchanger 2 Pump 3 Draining valve 4 Water buffer tank 5 Water filter 6 Non-return valve 7 Pressure expansion tank 8 Pressure point/drainage 9 Water outlet 10 Water inlet 11 Globe valve 12 Flexible pipes 13 By pass valve 14 Free-cooling coils 15 3 way valve SAFETY/CONTROL DEVICES A Inlet water temperature sensor chiller B Outlet water temperature se
English 4 - Installation (continued) Hydraulic Diagram - Slave / 1P D E 14 A E D 2 3 7 11 L Y I 1 8 11 H C 15 12 5 G 8 COMPONENTS 1 Plate heat exchanger 2 Pump 3 Draining valve 4 Water buffer tank 5 Water filter 6 Non-return valve 7 Pressure expansion tank 8 Pressure point/drainage 9 Water outlet 10 Water inlet 11 Globe valve 12 Flexible pipes 13 By pass valve 14 Free-cooling coils 15 3 way valve 10 INLET 8 13 B 11 8 SAFETY/CONTROL DEVICES A Inlet water temperature sensor chiller
4 - Installation (continued) Hydraulic Diagram - Slave / 2P D E 14 A C 6 D 2 E 3 7 11 1 I Y 8 6 L 15 12 5 G 11 10 INLET 8 13 2 8 8 B COMPONENTS 1 Plate heat exchanger 2 Pump 3 Draining valve 4 Water buffer tank 5 Water filter 6 Non-return valve 7 Pressure expansion tank 8 Pressure point/drainage 9 Water outlet 10 Water inlet 11 Globe valve 12 Flexible pipes 13 By pass valve 14 Free-cooling coils 15 3 way valve 11 H SAFETY/CONTROL DEVICES A Inlet water temperature sensor chiller
English 4 - Installation (continued) Hydraulic Diagram - Slave / 1P+T D E 14 E D A 3 7 11 2 I Y C 1 L 8 11 H 15 13 8 4 8 D 3 Y COMPONENTS 1 Plate heat exchanger 2 Pump 3 Draining valve 4 Water buffer tank 5 Water filter 6 Non-return valve 7 Pressure expansion tank 8 Pressure point/drainage 9 Water outlet 10 Water inlet 11 Globe valve 12 Flexible pipes 13 By pass valve 14 Free-cooling coils 15 3 way valve G 11 10 INLET 8 11 B 12 5 SAFETY/CONTROL DEVICES A Inlet water temperatur
4 - Installation (continued) Hydraulic Diagram - Slave / 2P+T D E 14 A 6 D E 2 3 7 11 I Y C 1 8 6 11 L 15 G 13 2 4 8 D 3 Y COMPONENTS 1 Plate heat exchanger 2 Pump 3 Draining valve 4 Water buffer tank 5 Water filter 6 Non-return valve 7 Pressure expansion tank 8 Pressure point/drainage 9 Water outlet 10 Water inlet 11 Globe valve 12 Flexible pipes 13 By pass valve 14 Free-cooling coils 15 3 way valve 12 5 11 10 INLET 8 8 B 11 H SAFETY/CONTROL DEVICES A Inlet water temperatur
4.4 Water connections WARNING 4.6 Electrical connections The unit must be installed on site according to the Machinery Directive 2006/42/EC, Electromagnetic Compatibility Directive 2014/30/EU and the usual procedures and standards applicable in the place of installation. The attachments at the water inlet and outlet shall be connected in compliance with the instructions which can be found on the labels in the proximity of the attachments.
4 - Installation (continued) Electrical Connections 18
WARNING NOTE 5.2 Start-up The unit must be started for the first time by personnel suitably trained by one Authorised Service Centre. Failure to meet this requirement will immediately void the warranty. Start-up sequence: The operations carried out by authorised personnel are limited to the start-up of the unit, and do not include any other operation on the plant, such as, for example, electrical and hydraulic connections etc. n Turn on the Main switch.
6 - Control 6 General information 6.2 Keypad functions Introduction KEY This document contains the information and the operating instructions for SysFreeCool units.
English 6 - Control (continued) 6.3 Folder structure 6.
6 - Control (continued) 6.6 Protection and Safety Equipment Frost Protection for the Chilled Fluid Fan protection These units are provided with frost protection for the chilled fluid. Setting FC04 value inside PAR/FC folder (Free-Cooling pre-freeze alarm deactivation set point), it is possible to set the temperature limit output value with active Free Cooling. FC04 value must be set according the freezing point of the glycol mixture.
7.1 General Information 7.6 Control Supply Panel Units are monobloc type, suitable to cool down water and glycol mixtures for any air conditioning application, cooling and process. These unit are completely factory assembled and equipped with all the plumbing and electrical connections that are needed for a quick installation in field. Once completed the assembly, a functional test is performed to check the tightness of the hydraulic system and the proper operation of the unit.
8 - Technical Data 8.1 Pressure drops PRESSURE DROP - SysFreeCool_ 12 14 22 23 24 32 33 34 43 44 Minimum flow rate l/s 3.1 3.5 4.8 7.5 8.0 7.5 10.4 11.0 15.1 16.0 Nominal flow rate l/s 5.3 8.2 10.7 12.8 14.4 16.1 19.2 21.5 25.6 28.7 Maximum flow rate l/s 8.3 9.4 13.1 20.4 21.6 20.2 28.2 29.8 40.9 43.
English 8 - Technical Data (continued) 8.2 Technical data SysFreeCool _ Power supply 12 14 22 23 V/ph/Hz 24 32 33 34 43 44 400 (± 10%) / 3 / 50 COILS Number of coils 2 2 4 4 4 6 6 6 8 8 m2 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.4 2.
8 - Technical Data (continued) 8.3 Unit electrical data SysFreeCool_ Rated voltage Max. absorbed power 12 14 22 23 V/ph/Hz 24 32 33 34 43 44 400 (± 10%) / 3 / 50 kW 4.2 4.2 8.4 8.4 8.4 12.6 12.6 12.6 16.8 16.8 Rated Current A 8.2 8.2 16.4 16.4 16.4 24.6 24.6 24.6 32.8 32.8 Max. current FLA A 8.2 8.2 16.4 16.4 16.4 24.6 24.6 24.6 32.8 32.8 Max. start-up current LRA A 8.2 8.2 16.4 16.4 16.4 24.6 24.6 24.6 32.8 32.
English 8 - Technical Data (continued) 8.4 Hydraulic features Pressure Drop Curves - SysFreeCool 100 12 14 22 32 24 33 34 43 44 100 [kPa] 10 23 10 30,00 3,00 [l/s] 8.5 Position of shock adsorbers and weight distribution on supports y SysFreeCool P1 P2 a C.G.Y b P3 P4 C.G.
8 - Technical Data (continued) 8.
English 8 - Technical Data (continued) Dimensions SysFreeCool 22-23-24 (stand-alone) CHILLER CHILLER SIDE SIDE C B A 584 P2 E D P1 B A A 681 2146 2146 2146 P4 P3 P1 SIZE 22 A B D E C 265 956 584 LIFT POSITION P2 AVM POSITION P4 P4 Back 2124view P2 P1 584 A 681 308 584 956 956 584 LIFT POSITION LIFT POSITION AVM POSITION AVM POSITION 2124 2124 B 496 584 B 2519 E E CHILLER DSIDE D B PLANT A SIDE 265 P3 P3 SIZES 23-24 A B D E C Water in 2-1/2” GAS M Water out 2-1/2” GAS M Wat
8 - Technical Data (continued) Dimensions SysFreeCool 32-33-34 (stand-alone) Side view B A 536 2056 P2 P2 LIFT POSITION AVM POSITION 3176 584 P4 P4 P2 P4 B A A 496 265 E D B 308 2519 308 20562056 LIFT LIFT POSITION POSITION AVMAVM POSITION POSITION 31763176 E D B 682 682 2146 A 2146 308 536 536 E D CHILLER SIDE 584 584 C 265 265 496 B B APLANT A SIDE C 496 C 2519 CHILLER CHILLER SIDESIDE PLANT PLANT SIDESIDE 2146 682 Back view SIZE 32 A B D E C P1 P1 P3 P3 P1 P3 SIZES
English 8 - Technical Data (continued) Dimensions SysFreeCool 43-44 (stand-alone) Side view PLANT SIDE P2 584 3060 3060 LIFT POSITION LIFT POSITION - AVM POSITION - AVM POSITION 4228 4228 P2 P4 P4 C P1 B P3 P3 P3 Water in 5” Victaulic Water out 5” Victaulic Water out 5” Victaulic Water in 5” Victaulic Electrical power supply 31 681 A 2146 P4 P1 SIZES 43-44 A B D E C 265 584 3060 LIFT POSITION - AVM POSITION 4228 Back view P1 681 2146 CHILLER SIDE E D P2 2146 584 B A 584 A 25
8 - Technical Data (continued) Dimensions SysFreeCool SyScroll 200 Air EVO FC 22 / SyScroll 230-280 Air EVO FC 23-24 / SyScroll Air 240-320 FC 23-24 (slave) Front view Side view 5670 5670 C PLANT SIDE B 265 AB 496 265 584 956 584 584 956 584 536 F 536 F 2056 584 2056 584 496 A 2520 2520 C PLANT SIDE B A 681 2146 2310 B A 681 (ONLY FOR MOVIMENTATION) 2146 2310 (ONLY FOR MOVIMENTATION) Back view FREE COOLING SIDE P2 956 P4 FREE COOLING SIDE P2 956 P4 CHILLER SIDE P3 2056 CHILLER S
English 8 - Technical Data (continued) Dimensions SyScroll 230-280 Air EVO FC 32 / SyScroll Air 240-320 FC 32 (slave) Front view Side view 6800 PLANT SIDE 2520 C 6800 A 2056 PLANT 536 SIDE LIFT POSITION 8Xø29 584 536 2056 584 584 536 2056 584 F 682 A 2146 2310 265 (ONLY FOR MOVIMENTATION) B A 536 2056 F LIFT POSITION 8Xø29 FREE COOLING SIDE P2 P4 2056 CHILLER SIDE P3 Back view FREE COOLING SIDE P2 P1 2056 2056 P1 CHILLER SIDE P4 P3 P3 P4 2056 P1 P2 AVM POSITION 8Xø17 P1
8 - Technical Data (continued) Dimensions SyScroll 300-360 Air EVO FC 23-24 (slave) Front view Side view 6800 6800 C C 2520 2520 PLANT SIDE PLANT SIDE 956 956 F F LIFT POSITION 8Xø29 584 584 584 584 3060 3060 584 584 LIFT POSITION 8Xø29 Back view FREE COOLING FREE COOLING P2 956 P3 P2 956 P3 P1 P1 P3 P3 CHILLER SIDE CHILLER 3060SIDE 3060 P1 P1 P4 P4 P4 P4 POSITION 8Xø17 AVM AVM POSITION 8Xø17 P2 P2 SYSCROLL 300-360 AIR EVO FC 23-24 A B C F Water in 3” GAS M Water out 3” GAS M Electrical po
English 8 - Technical Data (continued) Dimensions SyScroll 300-360 Air EVO FC 32 / SyScroll Air 360-420 FC 33-34 (slave) Front view Side view 7800 7800 C A PLANT SIDE536 2056 2056 536 584 F F 584 584 3060 3060 584 584 3060 584 584 B LIFT POSITION LIFT POSITION 8Xø29 8Xø29 682 682 AB A 2146 2146 265 2310 2310 (ONLY FOR (ONLY MOVIMENTATION) FOR MOVIMENTATION) B 536 2056 F LIFT POSITION 8Xø29 FREE COOLING SIDE SIDE FREE COOLING P2 P4 P2 P4 P3 P3 Back view FREE COOLING SIDE P2 P1 P1
8 - Technical Data (continued) Dimensions SyScroll Air 470-540 FC 33-34 (slave) Side view Front view 8900 8900 CC 2056 2056 FF 584 584 584 584 4112 4112 584 584 P4 P4 584 2056 2056 2056 P5 P5 584 2056 2056 P3 P3 4112 2056 2056 P1 P1 584 F LIFT POSITION 8Xø29 2056 P4 P3 P3 CHILLER SIDE P5 P6 P6 2056 P3 P4 P4 2056 P1 P2 P2 AVM AVMPOSITION POSITION10Xø17 10Xø17 P1 P3 P6 P4 P2 AVM POSITION 10Xø17 SYSCROLL 470-540 AIR FC 33-34 A B C F A 2146 682 2310 (ONLY FOR MOVIMENTATION) Back
English 8 - Technical Data (continued) Dimensions SyScroll Air 590-660 FC 43-44 (slave) Front view Side view 11000 11000 C 2520 2520 11000 265 265 496 496 BB AA 584 584 1540 1540 4208 4208 584 584 584 1540 4208 584 682 AA 682 2146 2146 2310 2310 265 (ONLY (ONLYFOR FORMOVIMENTATION) MOVIMENTATION) BB A 584 3060 F LIFT POSITION 8Xø29 FREE FREECOOLING COOLINGSIDE SIDE P2 P2 CHILLER CHILLERSIDE SIDE P4 P4 3060 3060 P5 P5 3060 3060 Back view FREE COOLING SIDE P2 3060 P1 P1 P3 P3 2104
8 - Technical Data (continued) 8.
9.3 Three-ways valve Carefully read the “Safety” section of this manual before carrying out any maintenance operations. During free-cooling operation (Free Cooling mode active), check that water temperature probes L1 (input) and L2 (output) give different values (taking also are about sensor tolerance).
10 - Troubleshooting The table below lists the anomalies of operation of the unit, the relevant causes and the corrective measures. For anomalies of any other type or not listed, contact one of authorised Service Centre for technical assistance. Anomaly The unit does not activate recovery function Excessive noise Fan motors not working Brine leakage from the safety valve Cause Operation Probe failure / wrong calibration. Replace. Servo-control failure. Replace.
English 11 - Spare Parts 11.1 Spare part list The table below shows the list of spare parts recommended during the first two years of operation. Component Number Fan 1 Flow switch 1 Display 1 Auxiliary circuit trasformer 1 Water sensor 4 Air sensor 1 Electronic main board 1 Fuses 4 11.2 Wiring diagrams The wiring diagrams are installed inside the doors of the electrical panels of the unit. Any request for wiring diagrams shall be forwarded to manufacturer’s Service Centre.
12 - Dismantling, Demolition and Scrapping If no shutoff valves have been provided, it may be necessary to drain the whole plant. DANGER If a glycoled solution or a similar fluid has been used in the hydraulic circuits, or if chemical additives have been added to the circulating water, the circulating fluid MUST be drained in a proper way. DANGER Some residues, glycoled water or similar solutions may remain in certain parts of the unit.
43 English Notes
Notes 44
Systemair srl Via XXV Aprile, 29 20825 Barlassina (MB) Italy Tel. +39 0362 680 1 Fax +39 0362 680 693 www.systemair.com As part of our ongoing product improvement programme, our products are subject to change without prior notice. Non contractual photos. Dans un souci d’amélioration constante, nos produits peuvent être modifiés sans préavis. Photos non contractuelles. In dem Bemühen um ständige Verbesserung können unsere Erzeugnisse ohne vorherige Ankündigung geändert werden.
